Grid nozzle assembly, a fluidized bed reactor with a grid nozzle assembly and methods of using a grid nozzle assembly

ABSTRACT

A grid nozzle assembly for a fluidized bed reactor, a fluidized bed reactor with a grid nozzle assembly, a method of mounting a grid nozzle assembly as a replacement in a fluidized bed reactor, and a method of replacing a grid nozzle assembly in a fluidized bed reactor. The reactor includes a horizontally extending bottom plate, a gas plenum chamber below the bottom plate, and vertical gas pipes having a top end and extending from the gas plenum chamber upwards across the bottom plate. The nozzle assembly includes a nozzle head with a gas channel for injecting fluidizing gas from one of the vertical gas pipes to the reaction chamber and a tube sleeve adapted to be firmly fixed by welding around the top end of the vertical gas pipe. The nozzle head and the tube sleeve form a twist-lock enabling quick connecting and disconnecting.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a grid nozzle assembly for a fluidized bed reactor, a fluidized bed reactor with a grid nozzle assembly, a method of mounting a grid nozzle assembly as a replacement in a fluidized bed reactor and a method of replacing a grid nozzle assembly in a fluidized bed reactor.

2. Description of the Related Art

In fluidized bed reactors, such as circulating or bubbling fluidized bed boilers or gasifiers, chemical reactions are performed in a reaction chamber in a fluidized bed of particles, such as sand or ash or fuel particles. The bed is fluidized by bringing fluidizing gas, such as combustion air, to the reaction chamber from a gas plenum chamber, usually so-called wind box, through a bottom grid of the reaction chamber. The bottom grid comprises grid nozzles through which the gas is injected in a predetermined, relatively high velocity and predetermined direction to the reaction chamber. The grid nozzles can also be used for removing solid particles from the bottom of the reaction chamber.

The conditions in the reaction chamber are often relatively harsh due to high temperatures, chemical attack of compounds formed in the reaction chamber or erosion caused by bed particles entrained with the fluidizing gas. Due to the harsh conditions, there is often a need to regularly replace grid nozzles by new ones. The replacement has to be done during relatively short outage times of the fluidized bed reactor. Because there can be several thousands of grid nozzles in the bottom grid of a fluidized bed reactor, the easiness of the replacement of the grid nozzles is of great importance.

Commonly used grid nozzles of fluidized bed reactors are made of steel and comprise a vertical tube or gas pipe that is welded to a bottom plate of the reaction chamber and a head portion, so-called nozzle head, through which the fluidizing gas is guided horizontally or slightly downwards to the fluidized bed reactor either as evenly distributed to all directions or as directed to a certain direction. The bottom plate and a lower portion of the vertical tubes are usually covered by a protecting refractory layer. During the operation of the fluidized bed reactor, a portion of the vertical tubes may also be embedded in stagnant or slowly moving bed particles, whereas the head portions are directly exposed to the harsh conditions. Thus, the nozzle heads are especially prone to deterioration. Also it is typical to fluidized bed reactors that some ash may enter in the fluidizing gas being supplied to the fluidized bed reactor. Due to the ash, there is a risk for high velocity ash erosion to occur inside the grid nozzles, increasing the need for frequent maintenance. Thus, there is a need for grid nozzles, the nozzle heads of which can be easily replaced.

In conventional grid nozzles, such as those shown in Canadian Patent No. 1151474, the vertical tube and the nozzle head are of one piece, or they are welded together so as to form a monolithic, integral piece. Thus, when there is a need to replace the nozzle head, it is common practice to cut the vertical tube and weld a replacement part with a new nozzle head around the upper end of the remaining portion of the vertical tube. This is a relatively slow process, which tends to each time shorten the remaining tube. It also gives rise to a considerable amount of harmful metal debris, which has to be removed from the bottom grid.

U.S. Pat. No. 3,708,887 shows a grid nozzle in which the vertical tube comprises an external thread and a tubular member of a nozzle head comprises a corresponding internal thread so as to connect the nozzle head to the vertical tube. Such a threaded nozzle head coupling is not suitable for many large scale fluidized bed reactors because the thread is relatively slow to open, and it may easily become stuck during the operation of the reactor.

International Patent Publication No. WO 2010/011457 A2 shows a grid nozzle, in which around the upper end of a vertical tube is welded a sleeve with an internal thread, and a lower portion of a tubular nozzle head comprises a corresponding external thread so as to connect the nozzle head to the sleeve. The connection of the tubular nozzle head to the sleeve is secured by tack welds between an outer rim of the nozzle head and the upper edge of the sleeve. This nozzle grid construction is also relatively slow to open and may deteriorate or become stuck during the operation.

An object of the present invention is to provide a new grid nozzle assembly that at least partially minimizes above described problems of prior art.

SUMMARY OF THE INVENTION

According to one aspect, the present invention provides a grid nozzle assembly suitable to be mounted in a reaction chamber of a fluidized bed reactor comprising a horizontally extending bottom plate, a gas plenum chamber below the bottom plate, and vertical gas pipes having a top end and extending from the gas plenum chamber upwards across the bottom plate, wherein the grid nozzle assembly comprises a nozzle head with a gas channel for injecting fluidizing gas from one of the vertical gas pipes to the reaction chamber and a tube sleeve adapted to be firmly fixed by welding around the top end of the gas pipe, wherein the nozzle head and the tube sleeve form a twist-lock enabling quick connecting and disconnecting the nozzle head and the tube sleeve.

The nozzle head comprises advantageously a horizontally extending top portion and a downwards extending stem adapted to completely fit into the tube sleeve, i.e., the stem fits into the tube sleeve so that the horizontally extending top portion makes a direct contact with an upper surface of the tube sleeve, to convey the fluidizing gas from the gas pipe to the gas channel of the nozzle head and to form the twist-lock with the tube sleeve.

According to a preferred embodiment of the present invention, the internal surface of the tube sleeve comprises at least one groove, comprising a vertical groove portion extending from an upper end of the tube sleeve to a central portion of the tube sleeve and a horizontally extending groove portion in connection with the lower end of the vertical groove portion and extending a predetermined angle from a lower end of the vertical portion. The predetermined angle is preferably from about 10 degrees to about 160 degrees, even more preferably from about 20 degrees to about 90 degrees, most preferably about 30 degrees.

The outer surface of the stem comprises correspondingly at least one nob fitting in the at least one groove so as to enable twist-locking the nozzle head with the tube sleeve by inserting the nob into the vertical groove portion, sliding the stem downwards in the tube sleeve so far that the nob reaches the lower end of the vertical groove portion, and twisting the nozzle head so as to move the nob in the horizontal groove portion. Usually the internal surface of the tube sleeve comprises two grooves as described above arranged opposite to each other, and the outer surface of the stem comprises correspondingly two nobs fitting in the grooves, but the number of grooves and nobs can be one or even more than two.

As mentioned above, the stem is advantageously adapted to completely fit into the tube sleeve, i.e. when the nozzle head is seated in its mounting position in connection with the tube sleeve, the top portion of the nozzle head, or, more precisely, a horizontally extending lower surface of the top portion, is in contact with the upper surface of the tube sleeve. Thereby, the arrangement enables efficient securing of the twist lock, i.e. preventing accidental twisting of the nozzle head, by a tack-weld, or tack welds, formed between the lower surface of the top portion and an outer surface of the tube sleeve. By arranging the tack weld or tack welds below the lower surface of the top portion, the top portion effectively protects the tack welds from the moving fluidized bed particles and thus minimizes erosion caused by the bed particles.

Each of the horizontally extending groove portions is advantageously slightly slanted from the vertical groove portion downwards so as to enable efficient tightening of the lower surface of the top portion of the grid nozzle towards the upper surface of the tube sleeve. By having the top portion tightened towards the tube sleeve, the tack welding is made easier. Even more importantly, a tight contact between the top portion and the tube sleeve efficiently prevents migration and sticking of fine bed particles between the tube sleeve and the nozzle head, without having to weld around the whole seam between the nozzle head and the tube sleeve. Thereby, the present mounting system enables quick and efficient way of minimizing the risk of damaging of the internal surface of the tube sleeve and/or unreplaceable sticking of the nozzle head to the tube sleeve.

In order to avoid turbulence in the gas flow within the grid nozzles, and internal erosion caused by particles entrained with the gas flow, the diameter of the gas flow path is preferably constant throughout vertical gas pipe and the vertical portion of the gas channel. Therefore, the diameter of the bore of the stem preferably corresponds to that of the vertical gas pipes. Correspondingly, in order to avoid any discontinuity in the gas flow path at the joint of the nozzle head and the vertical gas pipe, the length of the stem is advantageously adapted so that the stem substantially tightens with the vertical gas pipe when the lower surface of the top portion of the nozzle head is tightened to the upper surface of the tube sleeve.

When grid nozzles according to the present invention are mounted in a fluidized bed reactor, the tube sleeves are firmly fixed to the vertical gas pipes, preferably by welding. According to a preferred embodiment, each of the tube sleeves comprises at least one opening, preferably two oppositely arranged openings, to allow fixing the tube sleeves to the gas pipes by plug-welding. Another possibility is to contour the lower edge of the tube sleeves so as to form areas for fillet welds. When there is sufficient space from the tube sleeves to the bottom plate, or to a refractory layer on the bottom plate, it is also possible to fix the tube sleeves to the vertical gas pipes by using full circumferential welds.

According to an aspect, the present invention provides a fluidized bed reactor comprising a horizontally extending bottom plate, a gas plenum chamber below the bottom plate, multiple vertical gas pipes having a top end extending from the gas plenum chamber upwards across the bottom plate multiple, and multiple grid nozzle assemblies according to any of the embodiments described above, wherein the tube sleeves of the grid nozzle assemblies are firmly fixed around the top ends of the vertical gas pipes by welding, for example, by plug-welding, fillet welding or full circumferential welding.

According to a further aspect, the present invention provides a method of mounting a grid nozzle assembly as a replacement in a fluidized bed reactor comprising a horizontally extending bottom plate, a gas plenum chamber below the bottom plate, and multiple vertical gas pipes having a top end and extending from the gas plenum chamber upwards across the bottom plate, wherein the method comprises the steps of mounting a grid nozzle, in accordance with any of the above described embodiments, in the fluidized bed reactor by firmly fixing the tube sleeve by welding, for example, by plug-welding, fillet welding or full circumferential welding, around the top end of one of the gas pipes.

It is possible to firstly fix the tube sleeve firmly to the top of the gas pipe and only after that perform the easily removable tack-welding of the nozzle head to the tube sleeve. According to another possibility, the nozzle head is firstly tack-welded to the tube sleeve and only after that the tube sleeve is firmly fixed to the top of the gas pipe. An advantage of the latter possibility is that the tack-welding can be performed is desired conditions and only the firm fixing is performed in more demanding conditions, in the reaction chamber. Thus, according to an aspect, the present invention provides also a grid nozzle assembly comprising a nozzle head and a tube sleeve, according to any of the embodiments described above, which nozzle head is removably tack welded to the tube sleeve so as to allow quick disconnecting the nozzle head and the tube sleeve.

According to a still further aspect, the present invention provides method of replacing the nozzle head of a grid nozzle assembly according to any of the above described embodiments of the present invention, and comprising a nozzle head that is tack-welded in a tube sleeve, by disconnecting and connecting a twist-lock between the nozzle head and the tube sleeve. Thus, the method comprises removing the tack weld or tack welds from between the nozzle head and the tube sleeve, twisting the nozzle head while keeping the tube sleeve in place and sliding the nozzle head upwards so as to remove the nozzle from the tube sleeve, sliding a new nozzle head downwards in the tube sleeve, twisting the new nozzle head in the tube sleeve and securing the new nozzle head to the tube sleeve by forming a new tack weld.

Because the twist-lock of a used grid nozzle to be replaced may be fairly tight, the outer surface of the tube sleeve advantageously comprises flat surfaces, such as two opposite to each other arranged flat surfaces, to enable firmly holding the tube sleeve while twisting the nozzle head. Thereby it is possible to exert relatively high torsional momentum to the nozzle head without risk of damaging the gas pipe.

The above brief description, as well as further objects, features, and advantages of the present invention will be more fully appreciated by reference to the following detailed description of the currently preferred, but nonetheless, illustrative, embodiments in accordance with the present invention, when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a schematic view of a fluidized bed reactor with grid nozzles.

FIG. 2 shows a schematic side view of a grid nozzle according to an embodiment of the present invention.

FIG. 3 shows a schematic cross-sectional view of a nozzle head of a grid nozzle assembly according to an embodiment of the present invention.

FIGS. 4 a and 4 b shows schematic cross-sectional views of a tube sleeve of a grid nozzle assembly according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The schematic diagram of FIG. 1 shows a fluidized bed reactor 10 having a reaction chamber 12. The reaction chamber comprises a horizontally extending bottom plate 14 and a gas plenum chamber 16, so-called wind box, below the bottom plate. In the fluidized bed reactor 10, which can be, for example, a circulating or bubbling fluidized bed boiler or gasifier, chemical reactions are performed in the reaction chamber 12 in a fluidized bed of particles, such as sand or ash or fuel particles. The bed is fluidized by bringing fluidizing gas, such as combustion air, to the reaction chamber 12 from the wind box 16 through a bottom grid of the reaction chamber. The bottom grid comprises multiple grid nozzles 18 through which the fluidizing gas is injected in a predetermined, relatively high velocity and predetermined direction to the reaction chamber. In practice a fluidized bed reactor comprises also many other parts, such as fuel feeding nozzles, an exhaust gas channel etc. However, because such parts are not relevant for the present invention, they are omitted from FIG. 1.

The grid nozzles 18 are formed of vertical gas pipes 20 extending from the wind box 16 upwards across the bottom plate 14 and nozzle heads 22 comprising a gas channel for injecting fluidizing gas from a gas pipe 20 to the reaction chamber. Nozzle heads are attached to the gas pipes by the use of tube sleeves 24. According to the present invention, the tube sleeves are firmly fixed by welding around the top ends of the gas pipes but the nozzle heads are connected to the tube sleeves by a twist-lock, enabling quick connecting and disconnecting the nozzle head and the tube sleeve, as will be described more in detail in conjunction with the schematic diagrams of FIGS. 2-4. The same or corresponding elements are indicated in the different drawings by same reference numbers.

FIG. 2 schematically shows a side view of a grid nozzle 18 in accordance with an embodiment of the present invention, connected to a bottom plate 14 of a fluidized bed reactor. FIG. 2 shows a conventional gas pipe 20 which is attached to the bottom plate 14 by any conventional means, usually by welding, not shown in FIG. 2. A tube sleeve 24 is firmly fixed in an upper end 26 of the gas pipe 20 by a plug-weld 28. Usually there are two plug-welds on opposite sides of the tube sleeve. It is alternatively possible to fix the tube sleeve to the vertical gas pipe by another type of welding, such as fillet welding or full circumferential welding. A nozzle head 22 is connected to the tube sleeve 24 by a twist-lock 30, to be explained below, which is secured by tack welds 32. The tack welds are advantageously arranged below a horizontally extending lower surface 33 of the top portion of the nozzle grid, to protect the tack welds from erosion caused by moving bed particles.

FIG. 3 depicts a cross-sectional view of a nozzle head 22 according to an embodiment of the present invention. The nozzle head comprises a horizontally extending top portion 34 and a downwards extending stem 36. A gas channel 38 extends from the lower end of the stem to outlets branches 40 extending to lateral ends of the top portion 34. The outlet branches shown in FIG. 3 are slanted downwards to inject fluidizing gas towards the bottom plate, but the outlet branches may alternatively be directed differently, for example horizontally. The top portion 34 comprises two outlet branches 40, but the nozzle head may alternatively comprise only one outlet branch, to inject the fluidizing gas to a certain direction, for example, to move solid particles on the bottom plate to a certain direction. It is also possible that the nozzle head comprises more than two outlet branches to distribute the fluidizing gas evenly to the reaction chamber.

The stem 36 is adapted to fit into a tube sleeve 24, to be connected to a vertical gas pipe 20 connected to the bottom plate 14 of a fluidized bed reactor 10. Thus, the stem is a mainly hollow cylinder having a bore diameter which corresponds to the bore diameter of the gas pipes. In order to form a twist-lock with the tube sleeve, the stem comprises two nobs 42 on opposite sides of the outer surface of the stem. Alternatively there may be only one nob, or there may be more than two nobs. The purpose and function of the nobs 42 and their relation to corresponding grooves in the inner surface of the tube sleeve will be explained below in conjunction with FIGS. 4 a and 4 b.

FIG. 4 a schematically shows a horizontal cross-sectional view of the tube sleeve 24, and FIG. 4 b correspondingly shows a vertical cross section B, as shown in FIG. 4 a, of the tube sleeve 24. On the internal surface 44 of the tube sleeve are formed two identical grooves 46 comprising a vertical groove portion 48 and a horizontally extending groove portion 50. The depth of the groove corresponds to the height of the nobs 42 shown in FIG. 3 so that they form a twist-lock to connect the nozzle head 22 with the tube sleeve 24.

The twist-lock is closed by inserting the nobs 42 of the stem into the vertical groove portions 48, sliding the stem downwards in the tube sleeve so far that the nobs reach the lower end 52 of the vertical groove portions 48, and twisting the nozzle head so as to move the nobs 42 in the horizontally extending groove portions 50. Preferably the horizontal groove portions 50 extend horizontally a predetermined angle, such as about 30 degrees, from the lower end 52 of the vertical groove portion 48. The twist-lock can be secured by tack-welds 32 shown in FIG. 2. The twist-lock is opened by removing the tack welds, for example, by grinding, and performing the steps of closing in a reversed order.

In FIGS. 4 a and 4 b, the internal surface 44 of the tube sleeve 24 comprises two grooves 46, arranged opposite to each other, and the outer surface of the stem 36 comprises correspondingly two nobs 42 fitting in the grooves, but the number of grooves and nobs can alternatively be one, or even more than two.

The horizontally extending groove portions 50 are in FIGS. 2 and 4 b shown as horizontal, but they are in practice advantageously slightly slanted from the vertical groove portion 48 downwards so as to enable efficient tightening of the lower surface of the top portion 33 of the grid nozzle towards the upper surface of the tube sleeve 24.

FIG. 4 a shows one opening 54 in the tube sleeve 24 for forming a plug-weld with a vertical gas pipe in a bottom plate of a fluidized bed reactor. The number of openings can, however, alternatively be more than one, for example two. FIGS. 4 a and 4 b show a tube sleeve 24 with a cylindrical outer surface, but a portion of the outer surface, for example a portion of two opposite sides of the tube sleeve may advantageously be made flat, so as to make it easier to hold the tube sleeve 24 in place while a nozzle head 18 is twisted to remove it from the tube sleeve.

While the invention has been described herein by way of examples in connection with what are at present considered to be the most preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but is intended to cover various combinations or modifications of its features, and several other applications that are included within the scope of the invention as defined in the appended claims. 

We claim:
 1. A grid nozzle assembly suitable to be mounted in a reaction chamber of a fluidized bed reactor comprising a horizontally extending bottom plate, a gas plenum chamber below the bottom plate, and vertical gas pipes having a top end and extending from the gas plenum chamber upwards across the bottom plate, wherein the grid nozzle assembly comprises a nozzle head with a gas channel for injecting fluidizing gas from one of the vertical gas pipes to the reaction chamber and a tube sleeve adapted to be firmly fixed by welding around the top end of the vertical gas pipe, wherein the nozzle head and the tube sleeve form a twist-lock enabling quick connecting and disconnecting the nozzle head and the tube sleeve.
 2. A grid nozzle assembly according to claim 1, wherein the tube sleeve comprises an upper surface and the nozzle head comprises a horizontally extending top portion and a downwards extending stem adapted to fit into the tube sleeve so that the horizontally extending top portion is in direct contact with the upper surface of the tube sleeve, to convey the fluidizing gas from the vertical gas pipe to the gas channel and to form the twist-lock with the tube sleeve.
 3. A grid nozzle assembly according to claim 2, wherein the tube sleeve comprises an upper end, a central portion and an internal surface with at least one groove, the at least one groove comprising a vertical groove portion extending from the upper end of the tube sleeve to the central portion of the tube sleeve and a horizontally extending groove portion in connection with a lower end of the vertical groove portion and extending a predetermined angle from the vertical portion, and the stem comprises an outer surface with at least one nob fitting in the at least one groove so as to enable twist-locking the nozzle head with the tube sleeve by inserting the nob into the vertical groove portion, sliding the stem downwards in the tube sleeve so far that the nob reaches the lower end of the vertical groove portion, and twisting the nozzle head so as to move the nob in the horizontal groove portion.
 4. A grid nozzle assembly according to claim 3, wherein the internal surface of the tube sleeve comprises two or more grooves, each of the grooves comprising a vertical groove portion extending from the upper end of the tube sleeve to the central portion of the tube sleeve and a horizontally extending groove portion extending the predetermined angle from the lower end of the vertical portion, and the outer surface of the stem comprises two or more nobs fitting in the two or more grooves so as to enable twist-locking the nozzle head with the tube sleeve.
 5. A grid nozzle assembly according to claim 4, wherein the predetermined angle is from about 10 degrees to about 160 degrees.
 6. A grid nozzle assembly according to claim 5, wherein the predetermined angle is from about 20 degrees to about 90 degrees.
 7. A grid nozzle assembly according to claim 6, wherein the predetermined angle is about 30 degrees.
 8. A grid nozzle assembly according to claim 3, wherein the tube sleeve comprises an outer surface and the top portion of the nozzle head comprises a horizontally extending lower surface enabling to secure the twist lock by at least one tack-weld between the lower surface of the top portion and the outer surface of the tube sleeve so that the top portion protects the at least one tack weld by minimizing erosion of the at least one tack weld caused by moving fluidized bed particles.
 9. A grid nozzle assembly according to claim 8, wherein the horizontally extending groove portion is slanted from the vertical groove portion downwards so as to enable tightening the lower surface of the top portion towards the upper surface of the tube sleeve by the twisting of the nozzle head.
 10. A grid nozzle assembly according to claim 9, wherein the length of the stem is adapted so that the stem tightens to the vertical gas pipe when upper surface of the tube sleeve is tightened to the lower surface of the top portion.
 11. A grid nozzle assembly according to claim 1, wherein the tube sleeve comprises at least one opening or a contoured lower edge to allow firm fixing of the tube sleeve around the top end of the vertical gas pipe by plug-welding or fillet welding, respectively.
 12. A grid nozzle assembly according to claim 1, wherein the tube sleeve comprises an outer surface and the outer surface of the tube sleeve comprises flat surface portions to enable firm holding of the tube sleeve while twisting the nozzle head, so as to prevent damaging the vertical gas pipe.
 13. A grid nozzle assembly according to claim 1, wherein the nozzle head is removably connected by at least one tack weld to the tube sleeve so as to allow quick disconnecting the nozzle head and the tube sleeve.
 14. A fluidized bed reactor comprising a horizontally extending bottom plate, a gas plenum chamber below the bottom plate, multiple vertical gas pipes having a top end extending from the gas plenum chamber upwards across the bottom plate multiple, and multiple grid nozzle assemblies according to claim 13, wherein the tube sleeves of the grid nozzle assemblies are firmly fixed around the top ends of the vertical gas pipes by welding.
 15. A method of mounting a grid nozzle assembly as a replacement in a fluidized bed reactor comprising a horizontally extending bottom plate, a gas plenum chamber below the bottom plate, and multiple vertical gas pipes having a top end and extending from the gas plenum chamber upwards across the bottom plate, wherein the method comprises the steps of mounting a grid nozzle according to claim 1 in the fluidized bed reactor by firmly fixing the tube sleeve around the top end of one of the vertical gas pipes by welding.
 16. A method of replacing a nozzle head of a grid nozzle assembly according to claim 3, mounted in a reaction chamber of a fluidized bed reactor, wherein the method comprises the steps of removing the at least one tack weld, twisting the nozzle head in the tube sleeve and sliding the nozzle head upwards in the tube sleeve so as to remove the nozzle head from the tube sleeve, sliding a new nozzle head downwards in the tube sleeve, twisting the new nozzle head in the tube sleeve and securing the new nozzle head to the tube sleeve by at least one tack weld. 